FI113742B - Female component, mounting device and disposable suction article - Google Patents

Abstract

A female component is provided for engaging a complementary hook component in a refastenable fastening device. The female component comprises a nonwoven web secured to a backing. The nonwoven web has characteristics that are specifically suited for entangling and holding the hooks of the mating hook component. The nonwoven web has a basis weight of between about 6 and about 42 grams/meter2. The nonwoven web may comprise, among other types of nonwovens, a carded web with fibers between about 2.5 cm. and about 13 cm. long, or a spunbonded web with continuous length fibers. The denier of the fibers should be between about 0.5 and about 15. The total area occupied by any bonds between the fibers comprising the nonwoven web is less than about six percent of the total area of the web. The nonwoven web is secured to the backing, preferably autogeneously. The total area occupied by both the bonds between the fibers comprising the nonwoven web and by the bonds between the nonwoven web and the backing is between about 10 percent and about 35 percent of the total area of the female component. A fastening device having a hook fastening component and a female component that comprises the nonwoven female component of the present invention is also provided. The fastening device can be used on disposable articles, such as disposable diapers.

Description

113742

Female component, mounting device and disposable suction cup

Field of the Invention

The present invention relates to a female component of a mechanical, reattachable fastening device. More particularly, the present invention relates to a low cost, nonwoven female component of such an attachment means.

Background of the Invention

Hook and loop re-attachable fastening means 10 are now widely used in many situations. Such re-fastening fasteners have been used in clothing, disposable articles and various miscellaneous articles such as seat belts and the like. Such means are used to provide a re-attachable bond between two or more articles or between multiple surfaces of the same article. In certain applications, these reattachable fasteners have replaced conventional buckles, zippers, buttons, snaps, lanyards and stitches.

A popular type of mechanical fastener nowadays widely used, which utilizes mechanical adhesion to provide a re-attachable bandage, is sold under the brand name "VELCRO". VELCRO fastening devices are described in detail in U.S. Patent No. 2,717,437, U.S. Patent No. 3,009,235, U.S. Patent No. 3,266,113, U.S. Patent 3,550,837, U.S. Patent 4,169,303, and U.S. Pat. '4,984,339.

i:: VELCRO fasteners utilize two components; male component and female component. Male and female components are often referred to as · hook and loop components, respectively. The hook component consists of a fabric comprising a plurality of flexible, upright Haan-shaped structural members. The female component of the fastener consists of a fabric having a plurality of upright loops on its surface. When the surfaces of the hook component and the loop component 30 are pressed against each other to close the fastener, the hook engages in the loops to form a plurality of mechanical bonds between the individual hook and loops. Once these bonds have been established, '; these components normally do not release under normal conditions. This is because it is very difficult to separate the components by trying to »35 remove all hooks at the same time. However, when the gradual peeling force is applied to the components, the irradiation can be easily performed. Because the hooks are made of a flexible material, they open easily under the peeling force to release the loops.

This type of fastening device has been found to be particularly useful in disposable articles such as disposable clothing, disposable diapers, disposable packaging, cardboard boxes and the like. Such fastening means provide a secure closing means. However, the use of existing fasteners of this type in disposable articles is limited because such fasteners are relatively expensive. The main reason that such fasteners are expensive is that their manufacturing costs are high. These high manufacturing costs are associated with both the hook and loop components of these devices.

Conventional hook and loop components are typically formed by making a fabric having a plurality of woven loops extending outward from the back. The loops can be provided by weaving a backing fabric containing complementary yarns to form the loops, or by knitting the loops into the fabric. In other hook and loop components, the loops may be formed by plating or correcting (i.e., folding and corrugating) methods. The hook components of such fastening devices are typically formed by cutting the loops later. The cut loops act as hooks for the hook component.

. ···. These methods usually produce expensive hook and loop fastening materials because they are relatively slow. The hook and loop components of such attachment devices are generally also made of the same relatively expensive material. This material is usually relatively expensive because the material used in the hook component must be flexible so that may detach from the loop components when the instrument is opened.

; i; A: There have been many attempts to make alternative types of female components for fasteners. However, such companies have generally suffered from: · 30 deficiencies.

U.S. Patent 3,694,867 issued to Stumpf on October 3, 1972, discloses a "separate lock" having a female component comprising ;;; a "fluffy" non-woven fabric and a backing layer made of a single bonded flexible adhesive. U.S. Patent No. 4,761,318 to Ott et al., Issued August 2, 1988; discloses a loop fastening that can be simultaneously formed and secured to a substrate without the need for any additional steps such as sewing or applying pressure-sensitive adhesives to the substrate. . The female components disclosed in these U.S. patents suffer from the disadvantage that they are still made by methods which involve the mechanical processing of fibers to form loops. The female components described therein are not significantly less expensive to fabricate than the conventional loop components.

U.S. Patent No. 3,708,833 issued to Ribich, et al on January 9, 1973, discloses a re-attachable fastening device having a female component comprising a web-like urethane foam attached to a support layer. The female component disclosed in Ribich, et al., Suffers from the disadvantage that foams typically do not have enough openings to penetrate the hook of conventional hook components. In addition, the strength of the net foam is generally not sufficient to hold such claws when forces are applied to the attachment means. Preparation of net foam is still a relatively expensive method.

U.S. Patent 3,905,071 to Brumlik, issued September 16, 1975, discloses a "push-through self-adhesive device". The device disclosed in Brumlik's patent does not appear to be suitable for use in a reattachable device utilizing a conventional compatible hook component 20 with flexible hooks. The device disclosed in Brumlik's patent is for use in securing one or more sheets of material between the engaging member and the receiving member. The adhesive part disclosed in the Brumlik patent states:. rigid and hard needle-like elements for the gripping elements. These needle-like elements are particularly unsuitable for use. . 25 on the surface of disposable absorbent articles. Thus, the presentation of Brumlik's Pali γ exam appears to be limited to devices that utilize: · 'parts of the grip structure adapted to penetrate and pass through a plurality of material plates: and to be located within the receiving portion.

As a result, disposable articles require a low cost j '30 fastening device. In particular, low-cost fasteners are needed whose performance is comparable to more expensive, commercially available fasteners.

; It is an object of the present invention to provide an improved low cost female component of a fastening device.

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It is still an object of the present invention to provide a low cost female component of a re-attachable fastening device without the fibers being processed into loops.

It is still an object of the present invention to provide a female component of a fastening device that can be used with both commercially available hook components having single flexible hooks and less expensive hook components having more brittle hooks than those currently in use.

These and other objects of the present invention will become readily apparent when considered in conjunction with the following description and when taken in conjunction with the accompanying drawings.

Summary of the Invention

The present objects are achieved by the female component of claim 1, the attachment means of claim 5 and the suction article of claim 15.

Preferred embodiments of the invention are set forth in the dependent claims.

The present invention provides a female component for attaching an additional hook component to a re-attachable fastening device. The female component of the present invention is capable of engaging the hook component. to a base having individual, blunt-ended hook elements extending outwardly from the base. The female component does not require conventional types of y *. there are some loops. Typically, the hooks are gripped by elements in which the female component has a relatively flat outward facing surface.

The female component of the present invention comprises at least one non-w V fabric woven on a backing. The function of this non-woven fabric is to take at least some of the hooks of the complementary hook component, and to adhere to them and to give the hooks a space that they can fill when taken in: ·. The backing is adjacent to the non-woven fabric and provides the basis for the non-woven fabric; 30 canvas. The nonwoven fabric has a basis weight of about 6-42 grams per square meter. The non-woven fabric may comprise, in addition to other types of felt, carded; a fabric having fibers of about 2.5 to 13 cm in length, or a spun fabric having a constant length of fibers. For fibers comprising a non-woven fabric, the denier is i from about 0.5 to about 15. The total area described by the plane in which any bond meets the non-woven ·. 35 fibers ("inter-fiber dressings") is less than about 10%, more preferably less than 6%, and most preferably less than about 2% to 5113742 of the total area of the fabric. The non-woven fabric is firmly attached to the back, preferably autogenously. is the projected plane depicted area that is filled with both non-woven fabric fiber bonds and non-woven fabric and background bindings.The plane-bound female size area is about 10-18 percent of the total non-woven fabric area.

The female component of the present invention is formed by a process comprising the steps of: a) providing a first material having a basis weight of about 6 to 42 g / m 2 and comprising a plurality of fibers wherein the base area occupied by all of the interstitial ten percent of the total area of the first material; b) providing a backing material; and c) bonding the first material and the backing material to form a umbilical component such that the total area occupied by both the fibers between the first material 15 and the first material and backing % of the total area of the heavy component.

Thus, the female component described above may be made less expensive than conventional loop components since the fibers do not need to be mechanically processed into individual loops.

The present invention also relates to a fastening device having a hook fastening component and a female component comprising a non-woven female component of the present invention. The hook fastening component comprises some well known hook fastening components known in the art and having a base. # .t 25 and several single, continuous searches from the platform. The hook component used can ;; Y also includes a cheaper hook component with weaker hooks than those used today. The female component and the complementary hook fastening component provide a secure closure that withstands shear stress and peeling forces encountered during use.

The present invention also relates to disposable articles and more particularly to a disposable diaper having such an improved fastening device.

Brief description of the drawings

Although the specification ends with the claims which disclose and clearly claim patent protection for the subject matter of the subject matter, which is understood to constitute the present invention, it is believed that the invention will be better understood from the following description in the accompanying drawings, in which: the invention will be better understood from the following description in connection with the accompanying drawings, in which:

Fig. 1 is a perspective view of a reattachable fastening device of the present invention.

Fig. 2 is a partially cut, plan view of the female component of the present invention shown in use with a disposable diaper tape fastening system (only part of which is shown).

Figure 3 is a side view of the fastening device shown in Figure 1.

Figure 4 is a side view of an alternative embodiment of the female component having a "skin-friendly" layer of fibers forming its first surface. (Figure 4 also shows the connection between the non-woven material and the background in slightly less schematic form).

Figure 4A is a much enlarged side view of an embodiment of a female component showing the thinning of nonwoven fabric fibers at the site of the bond.

Figure 5 shows a single Haan component of the hook component described in plan.

Figure 6 is a side view of the challenge shown in Figure 5.

Fig. 7 is a plan view of an alternative embodiment of a non-woven female component of the present invention showing a preferred arrangement of fibers in a non-woven fabric.

Fig. 8 is a simplified side view of the non-; ; an alternative embodiment of a woven female component having a background of · · * non-woven fabric.

Fig. 9 is a simplified side view of the non-fig. . 25 alternate embodiments of a female component having a background: Y woven fabric.

Figure 10 is a partially broken away perspective view of a disposable diaper which includes a fastening device of the present invention.

Fig. 11 is a schematic side view of a method for making the female component of the present invention, Y '30, Fig. 12 is a schematic front view of one type of patterned roll that can be used in the method shown in Fig. 11 (dimensions greatly increased).

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Detailed Description of the Invention

Retractable Attachment 1. General Features of Retractable Attachment

A preferred embodiment of the retractable fastening device of the present invention, the fastening device 20, is shown in Figure 1.

The fastening means 20 comprises a non-woven female component 22 of the present invention and an additional hook fastening component 24.

The male portion of the device, the hook fastening device (or simply "hook component") 24, comprises a substrate such as a fabric 26. The fabric 26 has an en-10 first surface 27 and a second surface 29. The fabric 26 includes a plurality of straight gripping elements or "hooks" 28. extending from the first surface 27. The claws 28 have ends 38. The ends 38 are from the first surface 27 at the upper end of the continuous arms or spindles 40.

The female portion of the device, the non-woven female component (or simply the "female component 15" 22, receives and engages the claws 28 of the hook component 24. The female component 22 shown in Figure 1 has a first outwardly facing surface 31 and a second inwardly facing surface 33. a woven fabric 30 attached to a backing 34. The nonwoven fabric 30 comprises a plurality of structural components or structural elements 20. These structural elements comprise fibrous elements (or simply. · · ·. "fibers") 36. Fibers 36 cling to hooks 28 of hook component 24.

The arrangement of parts of the female component 22 is shown in Figure 1. The non-woven fabric 30 is disposed over the backing 34. The non-woven fabric 30 is outwardly formed to form the first surface 31 of the female component 22. The non-woven fabric 30 is exposed that is available for engagement with the hooks 28 of the hook V component 24. The back 34 is inwardly directed so that it · · · v: is adjacent to and generally associated with the part to which the female component 22 is attached.

The fastening means 20 of the present invention operates as follows. The fastening means 20 is closed when the female component 22 and the hook component 24 are pressed against each other's surface. When this occurs, the jaws 28 are entangled in the fibers 36 of the nonwoven fabric 30. The nonwoven fabric 30 provides the jaws, particularly the ends 38 of the hooks 28, with space to accommodate when the fastening means 20 is closed. Background 34 provides a solid base for nonwoven fabric 30. With stitches 28 being '; 35 mechanically entangled in the fibers 36 or "attached" thereto (to the right 8 113742 of Figure 1 this portion of the fastener 20 is shown) the joint between the components withstands forces that may be exerted on the fastener 20.

The fastening means 20 is opened by peeling the hook component 24 off the female component 22 (or by peeling the female component 22 off the hook component 24 5). If the hook component 24 has flexible hooks, the peeling operation may cause the hooks 28 to bend so that they are released from mechanical adherence to the fibers of the nonwoven fabric 30. In other cases (particularly if the jaws 28 are relatively inflexible), the jaws 28 may be disassembled by breaking the fibers 36 of the female component 22. In either case, the jaws 28 will be detached and the ha-10 component 24 will be completely detached from the female component 22. .

The components of the reattachable fastening device 20 will be more fully discussed in the following section of this specification. The non-woven female component 22 of the present invention is discussed in Chapter 2 below. The Haka-15 component 24 is discussed in Chapter 3. Chapter 4 provides examples of uses of the retractable fastening device 20.

2. Non-woven female component

The non-woven female component 22 shown in Figures 1-3 is a preferred embodiment of the female 20 component of the retractable fastening device 20 of the present invention. Several alternative embodiments are shown in the figures following Figures 1-3. It should be understood that the female component 22 is shown in most of the figures in generally schematic form for simplicity. Female component 22 configuration and no. . the weaving of the fabric to the backing 34 resembles the actual product

• · I

;; · 'F · 25 more closely than that shown in Figure 4.

* · * '·' First, a number of terms are given definitions to assist the reader in understanding the present invention.

The term "non-woven female component" as used herein is intended to be a quick way to refer to a female component of an attachment device comprising a nonwoven fabric attached to a backing. It is not intended to limit the present invention to female components made entirely of non-woven materials. Thus, the backing 34 need not be, and in many cases is not, a non-woven fabric.

: The terms "fabric" or "layer" as used herein may refer to a plurality of: 35 sheets or fabrics of the type of material described below. Thus, these expressions are not limited to structures which are layers or sheets of a single material.

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The term "loop component" as used herein refers to a portion of a hook-and-loop type attachment device constructed to engage the hooks of the complementary hook component. The non-woven cord component 22 of the present invention could be thought of as a substitute for the loop component. Generally, however, the non-woven female component 22 does not require that the loops of the material be specifically designed to grip the hooks of the compatible hook component. The individual fibers 36 of the nonwoven fabric 30 typically function to entangle the hooks 28, although these fibers are not necessarily "looped".

The non-woven female component 22 of the present invention should have certain properties.

The non-woven female component 22 has features specifically adapted to receive the hook 28 of the compatible hook component 24. The fibers 36 of the non-woven fabric 30 serve to cling to the individual hooks 28 of the compatible hook component 15. The female component 22 utilizes at least one layer of fluffy cling to the hooks of the hook component 24 to store them. The female component 22 does not require the formation of continuous loops of material from the back. (Thus, for the purposes of the present invention, the female component 22 may be understood to be "loopless").

The term "loop" as used herein refers to a fibrous material which is curved or doubled to form a closed arc within which: a hook may be inserted. As used herein, the term "loop" also includes materials made by any of the processes of treating fibrous materials individually or together to form loops, whether or not the fibers are formed in a closed or partially open loop. However, for the purpose of the present invention, the term "loop" does not include a non-woven fabric * ..! fibers placed inside a fabric which have not been separately treated.

The female component 22 has an outwardly facing surface 31 that is relatively flat, planar, or flat compared to surfaces of conventional loop-30 components in which material loops can extend outwardly from the back. As used herein, the term "planar" includes surfaces resting on a single, relatively flat plane as shown in Figures 1-3, as well as surfaces that gradually curve as shown in Figure 4, but the term "planar" is not limited to these surfaces. Non-woven fabric: 35 The individual fibers 36 can rest relatively flat on the surface 31 of the non-woven fabric and need not be "looped". Although it is possible that 10 113742 they could be looped or foolish. However, such embodiments are less preferred.

The female component 22 should have sufficient space between the fibers 36 of the nonwoven fabric 30. The space should be sufficient to allow the claws 28 to easily enter the spaces (or gaps) between the fibers 36 of the non-woven fabric 30 when the hook component 24 is placed with the female component 22 against the surface. The staples 28 should be able to enter these fibers 26 without piercing them. The staples 28 should be able to enter these fibers 36 as needed and spread them apart. However, this should require the use of a relatively small, if any, force (e.g., compared to that required for the use of a "press-through" device as described in the Brumlik patent document discussed above).

When the female component 22 is provided with such a space between the fibers of the non-woven fabric 30, it interacts with conventional, commercially available hooks. However, the female component 22 is not limited to use with conventional hooks with flexible, flexible hooks. It can also be used with hook materials with cheaper, weaker hooks. The female component 22 is also particularly suitable for use with hook components having components having generally rounded and / or blunt ends at the hooks. It does not require the use of specially made rigid, sharp hooks. However, it is possible that sharp: '' '; hooks are used with the female component 22.

·· When the female component 22 of the present invention is said to be "capable of *" * engaging "the hook component with certain types of claws, this means:, ·. 25, that hook type components of the type referred to may be used. However, the female component 22 is not limited to use with such a hook component; other types of hook components may generally be used with the female heavy component.

The amount of open space 30 between the fibers 36 of the nonwoven fabric 30 required to operate the fastening means 20 relates to the size of the hooks 28 of the hook component 24. The dimensions of the various parts of one type of Haan 28 are shown in Figures 5 and 6. The overall height of Haan 28 shown in Figures 5 and 6 is h and the top 38 has a certain length, width and height, indicated by I, w and hi, respectively.

; 35 As used herein, the term "head" of the hooks refers to portions of the hook 28 that: extend laterally (or radially) outwardly of the stem 40 in one or more directions 11113742. Often there is no boundary between where the shaft 40 of the hook 28 ends and where the head 38 begins. For purposes of the present invention, the head 38 of the staples 28 is considered to begin with the portion of the stem 40 indicated by 43 in Figure 3B. This is that portion of the arm 40 which is perpendicular to the background 36 as the lowest point 45 of the head 38 of the hook 28. The lowest point 45 is that portion of the head 38 that is at least orthogonal to the base 26 of the hook component 24.

The length I and the width w of the hook head 38 are most important in determining the amount of open space required between the fibers 36 of the nonwoven fabric 38. More specifically, the required amount of open space 10 between the fibers 36 of the nonwoven fabric 30 is generally defined by dimensions known as the projected plane (or "projected plane projected dimensions") of the ends 38 of the hooks 28. This field is represented in Figure 5 by the reference letter Ah. This is the surface of the jaws 28 which initially contacts the female component 22 of the present invention. Thus, the open space imaged between the fibers 36 of the nonwoven fabric 30 should either be slightly larger in size than the projected planar dimensions of the ends 38 of the hooks 28 / the dimensions of the projected image in planes, or these fibers 36 should easily spread apart to these dimensions. Therefore, when using large hooks 28 (i.e., hooks with a relatively large Ah), there should be more open space than if relatively small hooks 28 were used.

Non-woven fabric 30 is a basic component of the female component 22 of the present invention. The non-woven fabric 30 is part of the female component 22 which allows at least some of the hooks 28 ··· of the complementary hook component 24 to receive and receive these hooks 28 and to give them the space they

f · M

....; meet when they are allowed in.

: 25 The non-woven fabric 30 used in the female component 22 may be any suitable non-woven material. The term "non-woven" as used herein refers to a fabric made of fibers held together by interlocking or bonding and not woven, knitted, felted, or the like.

The non-woven fabric used herein may be a structure consisting of fibers 30 which are initially substantially unbound and subsequently bonded to the backing 34.

; The non-woven fabric contemplated herein also includes fibrous fabrics having some degree of fiber bonding before these fabrics are bonded to the backing 34.

The non-woven fabric 30 should have the open space described above. The amount of open space 35 should be sufficient to allow multiple hooks 28 of the compatible hook component 24 to penetrate the non-woven fabric 30 in the thickness direction when the hook component 24 is placed with the female component 22 against the surface. However, it is not necessary that all hooks 28 of the hook component 24 penetrate into the non-woven fabric 30. The distribution and number of such open spaces should be sufficient per unit area of the female component 22 to accommodate a sufficient number of hooks 28 of the compatible hook component 24 for the fastener 20 to be useful.

Therefore, the non-woven fabric 30 should have some type of structure with sufficient space between the fibers 36 to allow the hook 28 of the compatible hook component 24 to enter. Alternatively, or in addition, the nonwoven fabric 30 may be a structure comprising fibers 36 arranged in a shape sufficiently flexible to displace the fibers 36 from the hooks 28 of the compatible hook component 24 when the hook component 24 is applied to the female component of the present invention. 22 with the surface facing the surface.

When the fastening means 20 is closed, the hooks 28 of the compatible hook component 24 first pass through the first surface 31 of the non-woven fabric 30 and into the interior of the non-woven fabric 30. The claws 28 may initially penetrate deeper in the non-woven fabric 30 than they ultimately are when they engage the fibers 36 of the non-woven fabric 30. In other words, there is usually first movement of the claws 28 inward (toward the back 34) and then outward 20 before as they adhere to the fibers 36 of the nonwoven fabric 30.

The non-woven fabric 30 should also be capable of engaging and holding a sufficient number of staples 28 of the compatible, hook component 24 to

• I

Therefore, the amount of fibers 36 comprising non-woven fabric 30 must be sufficient to engage the staples 28 so that the staples are held until the peeling force is applied to open the fastener. The strength of the fibers must also be sufficient to hold the claws 28: V when applying to the attachment means 20 forces that are not: intended to open.

Properties used in the field of non-woven fabrics, such as fiber> 30 basis weight, length, and denier, are used to distinguish non-woven materials having the properties disclosed above. The open area between the fibers 36 and the number of fibers (at least in relative terms) can be estimated from the basis weight of the fabric. (For example, a nonwoven fabric with a lower basis weight typically has a larger open area and less fiber than a fabric of greater than 35 square meters with the same denier and length of fiber.) The strength (at least relative) of the fabric for use in a female component the fiber denier and the material composition.

Preferably, the basis weight of the nonwoven fabric used in the female component 22 of the present invention should be relatively small so that there is sufficient space between the fibers 36 of the non-woven fabric 30 to penetrate into the non-woven fabric 30 of the prongs 28. having a basis weight of about 6-42 g / m 2, more preferably about 18-24 g / m 2. The square meter weight is measured by stamping a sample of a given size and weighing the sample with a standard scale. The sample weight and area 10 determine the sample weight per square meter. If necessary, the density of the sample can be calculated from the sample weight per square meter and its thickness.

The thickness of the non-woven fabric 30 should be sufficient to allow the ends 38 of the hooks to adhere to the fibers 36 of the non-woven fabric 30. Non-woven fabric 30 is typically relatively thicker (i.e., thicker or has a "puffiness" greater than 15) than backing 34. This is because it has to provide sufficient space for storage of ends 38 and, in many cases, at least storage. Non-woven fabric can therefore be called "fluffy" material.

The required thickness of the non-woven fabric 30 depends on the height 28 of the hooks 28 of the matching hook component 24. More specifically, the thickness depends on the dimension indicated by hi in Fig. 6, which represents the height of the hooks 28 ... ends 38. The thickness of the non-woven fabric 30 should be at least equal to the height hi of the ends 38 of the hooks 28. This ensures that there is room for the inward and outward movement of the staples 28 to adhere to the nonwoven fabric 30 in the fiber 36.

The thickness of the non-woven fabric 30 can vary as much as: the overall height h of the hooks 28 and more. For non-woven fabric 30: thus, there is no fixed upper limit. In some embodiments, the thickness of the non-woven fabric 30 may be determined such that the total thickness of the non-woven fabric 30 is ··· 30 approximately the height h of the staples 28 to ensure good fit ·. between the female component 22 and the matching hook component 28.

However, the thickness should preferably be only slightly greater than the height hi of the ends 28 of the hooks 28 of the matching hook component 24. If the thickness of the non-woven fabric 30 is any greater, much of the excess material used to obtain this extra thickness is not used and is in fact wasted.

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More specifically, the thickness of the non-woven fabric 30 may be, for example, sufficient to accommodate hooks of the size discussed in more detail in Chapter 3 below. For example, if the hooks 28 have a total height h of about 0.38-0.64 mm and a 0.3 mm, the thickness of the non-5 woven fabric 30 should generally vary from slightly greater than 0.3 mm to about 0.38 mm or about 0.64 mm, respectively. However, in some embodiments, the thickness of the non-woven fabric 30 may depend on the size of the hooks 28 of the more or less compatible hook component 24. For example, the thickness of the non-woven fabric 30 may be equal to about A or 1/4 of the thicknesses described above, or less if smaller proportions are used 28.

The non-woven fabric 30 preferably consists of relatively long fibers 36. The longer the fibers 36, the easier it is to tie these fibers to one another and to the backing 34. Unbound, loose fibers or partially bound fibers (e.g., fibers with only one end bound) can be excessive if extremely short fibers are used. Such fibers are unable to cling to and hold onto the hooks 28 of the hook component 24.

The lengths of the fibers 36 in the non-woven fabric 30 depend on the type of method used to make the non-woven fabric 30. For example, if carded non-woven fabric is used, the lengths of the fibers comprising such a fabric may range from about 1 thread to about 13 threads. Preferably, the fibers are about 5 cm to 8 cm long. If, on the other hand, spunbonded '' is used; Fabric, the fibers or filaments of such fabrics are typically of continuous length.

The diameter of the fibers 36 is one factor that determines the strength of the non-woven fabric: 25. Generally, the larger the fiber, the stronger the fiber. The maximum diameter that can be used depends, in part, on the size of the • V 48 hooks 28. The term "spacer" as used herein refers to openings formed by: T: the ends of the hooks 38 (those portions that adhere to the fibers 36). The diameter of the fibers 36 must not be so large that the ends 38 of the staples 28 cannot fit around the fibers 36 '. 30 and cling to them. For the currently available hook components, the fiber 36 of the nonwoven fabric 30 should have a denier of from about 2 to about 15, more preferably from about 3 to about 9, most preferably from about 3 to about 6. If hook components with substantially smaller claws 28 than those currently available are available, the fiber denier could be about 0.5 to 15 or less. It is possible that fibers with denier as small as about 0.5 to 1.0 or less could be used. Such fibers may be referred to as "microdimer fibers". (Denier is a unit of fineness of one gram of yarn for every 9,000 meters is 113742, so 100 denier yarn is finer than 150 denier yarn).

The orientation of the individual fibers 36 in the non-woven fabric is also important. The orientation of the fibers 36 in the preferred non-woven fabric 30 is preferably substantially in a single direction.

Further, when the female component 22 is attached to the disposable diaper retaining attachment means 20 (part shown in FIG. 2), the orientation of the fibers 36 in the non-woven fabric 30 relative to the edges of the diaper 50 is also important. In such cases, the fibers 36 of the non-woven fabric 30 are preferably oriented in a single direction (as shown in Figure 7) such that they are generally parallel to the longitudinal edges 60 of the diaper 50.

This orientation of the fibers 36 in the non-woven fabric 30 provides the greatest resistance to detachment of the staples 28 when the fastening means 20 is subjected to the forces typically encountered in a diaper fastening system. These forces 15 are generally exerted in the plane of the interface between the fastening components in a direction parallel to the end edges of the shell. The orientation of the fibers 36 considered above can be compared to a situation in which the fibers 36 are perpendicular to the longitudinal edges 60 of the shell 50. In this latter less desirable case, the fibers 36 would travel in the same direction as these forces 20 (or parallel to these forces). In the latter case, the fibers may not be able to act as the "trap" of the hooks 28 of the compatible hook component 24.

In other alternative embodiments (such as those shown in Figures 1-3), particularly when a lofted nonwoven fabric is required, the fibers 36 may be randomly oriented. If the fibers 36 of the non-woven fabric 30 are randomly oriented, the fibers 36 will "cross" and stack on top of each other to provide flair (or height). This provides an additional T space that can be filled by the hook 28 of the compatible hook component 24 when the hook component 24 engages the non-woven female component 22.

The orientation of the fibers 36 in the non-woven fabric 30 may be analogous to the arrangement of the logs. If several logs are placed side by side, the height of the group of logs is only equal to the diameter of the logs. However, if the logs are oriented in different directions, e.g., if stacked (for example, in a log house), the height of the stack would be equal to the sum of the diameters 35 of the stacked logs.

16 113742

Preferably, the fibers 36 in the non-woven fabric 30 may also be curled for extra frizz / thickness. The term "curled" as used herein means that the fibers 36 are wavy or bent in their longitudinal direction. The fibers 36 may be carded (preferably prior to carding or the like (however, the fibers of spunbonded fabrics are not usually carded)) by any suitable commercial carding method. Such non-woven fabric 30 preferably has at least about 4 folds / cm, and more preferably at least about 5.5 folds / cm.

The fibers of the nonwoven fabric 30 may be comprised of, but not limited to, any suitable ma-10 material including polyesters (such as polyethylene terephthalate (or PET), polyethylene and polypropylene, or any combination of these or other suitable materials known in the nonwoven fabric). For example, the nonwoven fabric 30 could comprise a blend of two different types of fibers (e.g., polyester and polypropylene fibers). In still other cases, non-woven fabric 30 could consist of fibers comprised of more than one material (e.g., polypropylene-coated polyester fibers). Suitable polypropylene fibers for such a non-woven fabric include those available from Hercules, Inc., Wilmington, Delaware under T-181, T-182, and T-196.

The amount of bonding between fibers 36 of the nonwoven fabric 30 is important for the female component 22 of the present invention. The bonding sites provided by the bonds between fibers 36 of the nonwoven fabric 30 tend to be "; To reduce any spreading of the fibers 36 to accommodate the staples 42. In addition, the excessive amount of fiber-to-fiber bonds 42 in the nonwoven web 25 will interfere with the entry of the hooks 28.

:.! : The amount of fiber-to-fiber bonding depends on the type of non-woven material used to prepare the female component 22. The non-woven fabric used: T: 20 could initially be unbound and then be bound during the manufacturing process of the female component 22. For example, the female component 22 30 could be made by bonding an unbound layer of loose fibers to the backing material, in which case there would be no inter-fiber bonds 42.

»

However, in order to facilitate manufacture, it may be advantageous to use a commercially available pre-bonded fabric. In this case, this fabric is bonded to the backbone 34. If the female component 22 is made of 35 pre-bonded non-woven fabric, there is a certain amount of inter-fiber bonding. In the latter case, these inter-fiber dressings should occupy less than about 10%, preferably less than about 6%, and most preferably less than about 2½% of the area of the nonwoven fabric. This ensures that the space introduced by the fiber-to-fiber bonds does not interfere with the penetration of the hooks of the compatible hook component 24.

Preferably, the concentration of inter-fiber bonds is measured by examining a representative sample of non-woven fabric under a microscope. (The following method is also preferably used to measure the proportion of the area occupied by the dressings between the nonwoven fabric 30 and the background 34. However, in the latter case, the properties of the entire female component 22 sample are investigated instead of the nonwoven fabric 30.) , 2 10 cm). The sample is viewed under a microscope directly above the site forming the first surface 31. The area depicted on the plane of each inter-fiber bond 42, which is the full thickness of the sample, is measured. The areas are calculated after the sizes of the dressings 42 have been measured using a precision gauge placed under the microscope lens.

15 The sum of the areas of the dressings 42 is divided by the sample area. The result is expressed as a percentage. This is the percentage of the area occupied by the fiber-to-fiber bonds 42. For the purposes of the present invention, if this percentage falls within any of the 6.5 square centimeter portion of the sample, the material in question is considered to fall within this specific range.

The non-woven fabric 30 is preferably also flexible. A flexible non-woven fabric 30 is particularly desirable when the attachment means is applied on the surface of the backside article. This allows the non-woven fabric 30 to continue to maintain a space that can be filled by hook 28 even after the non-woven female component 22 has been compressed during manufacture, packaging and use, or the like.

Preferably, the material used in the non-woven fabric 30 should be: relatively soft if the female component is used in the fastening system: on the surface of the disposable article so that the female component 22 is comfortable for the wearer if it contacts the wearer's skin.

The non-woven fabric 30 can be made soft by providing a non-woven fabric. dot fabric on 30 "skin friendly" surface. There are several ways to do this. For example, as shown in Figure 4, non-woven fabric 30 may be provided with a certain amount of relatively small denier (e.g., about 0.5 to 5 denier, preferably about 3 denier) fibers from its first surface 31. Because these: 35 smaller denier fibers are finer, they have a softer, less coarse surface for the wearer. The finer fibers may be provided in any suitable shape on the first surface 31 including but not limited to the shape of the layer.

Non-woven fabric 30 can be made by many different methods. For example, the non-woven fabric could be either carded or tied by spinning. Such non-woven fabrics may be made by any suitable commercial carding or spinning process.

Suitable materials for such a non-woven fabric 30 can be obtained in the form of carded non-woven fabric from the Veratech Nonwoven Group of the International Paper Company, Walpole, Massachusetts 02081 by specification as described herein (such as basis weight, fiber denier and composition). (However, inter-fiber bonds in the fabric must normally be measured as described above.) An example of a suitable carded nonwoven fabric that may be used in other embodiments of the female component 22 may include materials used as uppers in diapers or other disposable suction articles (provided that they have the properties explained here). Suitable spinning knit nonwoven fabrics can be obtained from the James River Corporation Nonwovens Division, located in Simpson Wool, South Carolina. (However, it is not specifically admitted that some of the materials described herein are known to be used in fasteners.) 20 The backing 34 is disposed below the nonwoven fabric 30. The backing 34 provides the basis for the non-woven fabric 30. The backing 34 serves as a surface to which the non-woven fabric 30 can be attached. However, background 34 is optional. As an example, in an alternative embodiment of the female component 22, there is no background * ··:. the non-woven and non-woven fabric 30 may be bonded directly to the substrate (the surface of the article to which the female component 22 is to be attached) and serve as a backing.

• i: Many types of materials are suitable for use as a background 34. The background: 34 should preferably be of a type such that the hook 28 of the compatible component 24 does not penetrate. The backing 34 could be a film, some other non-woven fabric as shown in Figure 8, or a woven fabric as shown in Figure 9. The backing 34 is usually a layer of material. Typically, background 34 is a film. The backing 34 may be made of polyester, polyethylene or polypropylene or any other suitable material. Suitable materials for use as backing 34 include commercially available low density (e.g., about 0.02 mm to 0.08 mm) polyester, 35 polyethylene, or polypropylene film. A suitable polypropylene film can be obtained as 19,117,442 as the product designated as JR-136 from the James River Corporation Food and Consumer Packing Group, Cincinnati, Ohio.

If the base comprises a disposable diaper backing, the backing layer may consist of any of the material above or similar materials. Typically, however, such a tablecloth consists of polyethylene.

The non-woven fabric 30 may be attached to the backing 34 by any suitable means.

To facilitate manufacture, the non-woven fabric 30 is preferably attached autogenously to the backing 34. The term "autogenously" as used herein means that the non-woven fabric 30 is attached to the backing 34 without the aid of a third material. The non-woven fabric 30 may thus be cast or melted into the backing 34.

The means used to hold the non-woven fabric 30 and the backing 34 together (binding means 44) must have a number of properties. The binding means 15 must not take up so much space that it prevents the hook 28 of the compatible hook component 24 from penetrating into and adhering to the non-woven fabric 30.

The bonding between the nonwoven fabric 30 and the backing 34 should be such that, when the female component 22 is made, the total area occupied by both the bonding between all fiber 20 and the nonwoven fabric 30 and backing 34 ("total bonded area" or simply ... "total area") is less than 35%, more preferably about 10% to 35%, most preferably about 10% to 18% of the area of the female component 22. The total bound area is measured in the same * * way as defined above to determine the space occupied by the fiber-to-fiber bonds: 25%. (However, the area of 46 bound areas is also taken into account in the calculations!) '.' The binding means 44 must also be strong enough that the entire non-woven fabric 30 is not detached from the background when the hooks 28 are detached. Binding means 44 may form bound regions, bound regions 46, which are either stronger or 30 weaker than fibers 36, which form nonwoven fabric 30. In preferred embodiments of the present invention, bound regions 46 are sufficiently strong to provide fibers 36 of nonwoven fabric 30. strength, so that when relatively stiff hooks are used, the fibers 36 of the non-woven fabric 30 are broken instead of being pulled loose from the binding sites.

35 This type of strength can be applied to bound areas 46 in the following manner. When the non-woven fabric 30 is autogenously bonded to the backing 34, the fibers 36 of the non-woven fabric 30 are "reduced by forming a neck" (they become thinner) from the locations indicated at 37 in FIG. 4A where they are bonded to the backbone. that the fibers 36 become thinner adjacent to the individual bound regions, bound regions 46, than at other locations 5 along the length of the fibers. This is because a little material comprising the fibers 36 melts to form a bond. This reduces the diameter of the fiber 36 near the binding site. Typically, in such cases, the fibers 36 will break near the binding site 46 in the "necked" portions 37.

This type of structure (the type where the bound regions 46 are stronger 10 than the nonwoven fabric 30 fibers) is preferred over the structures where the bound regions 46 are weaker than the nonwoven fabric 30 forming fibers 36. In the former case, if stiff hooks are used, the hooks 28 usually detach when the fiber 36 is close to the binding site 46, rather than relying on the bending of the hooks 36 to release the fibers 36. In a preferred type of structure, only one fiber 36 typically breaks when the hook 28 is detached. This results in only minimal sulfur tearing of the female component 22 as the hooks 28 are detached. There is, however, a considerable amount of fibers for the staples 28 which can adhere to the staples 28 the next time the fastening means 20 is closed.

On the other hand, if the binding sites 46 are the weakest structural member of the female component 22, each hook 28 may be capable of breaking multiple binding sites 46 when the fastening means 20 is opened. This could cause all ... fibers 36 of the non-woven fabric 30 to be completely or almost completely torn off the backing 34. If this occurs, the number of firmly attached fibers 36 available for gripping the staples 28 will be substantially reduced. Further, such loose female fibers tend to reduce the open space required by the claws 28 of the compatible hook component 24 to penetrate.

Possible types of bonding means 44 include, but are not limited to, ultrasonic, thermal: pressure / pressure, and adhesive dressings.

The type of binding means 44 used may be limited to some extent 30 by the types of materials used for the nonwoven fabric 30 and the backing 34. This is especially true if the bonding means 44 are ultrasonic or heat / pressure dressings. When using these two types of bonding means 44, the materials constituting the non-woven fabric 30 and the backing 34 should be compatible with the type of material and the melting point of the material. As used herein, the term "compatible" means that the materials can be fused together.

21 1 13742

When the materials are described herein as being "similar", it is meant that the materials are generally formed of the same compound as polypropylene. However, similar materials may comprise two types of such material (for example, two different polypropylene materials).

The pattern in which the bound regions 46 are arranged is also important. The binding pattern may be either continuous or any suitable type of intermittent pattern. Some of the 10 bond patterns shown in U.S. Patent Application Serial No. 07 / 355,065, entitled "Loop Fastening Material for a Fastening Device and Method of Making the Same", filed May 17, 1989 by John R. Noel et al. suitable provided that the binding pattern meets the criteria disclosed herein.

The continuous bonding pattern is often advantageous in that the fibers 36 in the non-woven fabric 30 are more likely to adhere firmly.

A discontinuous pattern providing relatively small spaces or breaks 15 between bound regions 46 should also be appropriate. An example of a broken interlocking pattern is given in the upper left corner of Fig. 7 for purposes of illustration and is not a limiting example. The breaks 46 'between the bound regions 46 of such a discontinuous pattern should be small enough that the non-woven fabric 30 has relatively few fibers 36 with the ends cut off. It is believed that a discontinuous binding pattern 20 in which the breaks 46 'between the bound regions 46 are equal to or smaller than the smallest diameter fibers are suitable. Larger breaks 46 'between bound regions 46 may also be appropriate. For example, in some cases, the breaks 46 'between the bound regions 46 could be VA times or even 5 times (or possibly more than 25 pounds) as large as the smallest diameter in the non-woven fabric 30:. having a fiber diameter.

«·

If a discontinuous binding pattern is used, another important factor is the frequency of the interruptions 46 'in the pattern. If breaks occur too frequently, there will be too many fibers 36 with loose ends. It is preferred that the bound regions 30 46 are longer (occupy more area) than the breaks 46 'on each of the broken lines in the binding pattern.

The pattern of the bound regions 46 is preferably rectangular. Suitable bonding patterns include continuous or discontinuous lines. Such lines may be curved, e.g. sinusoidal, or may be arranged in the form of grids 35 defining various geometric shapes such as squares, rectangles, spheres, diamonds, and circles. This gives the female component 22 relatively uniform gripping properties.

Preferably, the bound regions 46 are close enough to each other so that the fibers 36 of the nonwoven fabric 30 have relatively few unbound loose ends 5. To ensure this to occur, the spacing between the bound regions 46 should preferably be less than the average length of the fibers 36 in the non-woven fabric 30, more preferably less than or equal to about half the length of the fibers 36 in the non-woven fabric. (The specified distance between bound regions 46 refers to states other than 10 breaks 46 'in the discontinuous binding pattern.)

The diamond-shaped pattern shown in Figure 7 is a preferred bonding pattern. "" Diamonds "are usually square elements in the" diamond-shaped "pattern. These elements are rotated about 45 degrees to give the diamond the appearance. The dimensions of the pattern should be such that the distance between the bound regions 46 is at least some portion of the bound regions projected, planar dimensions of the ends 38 of the hooks 28 of the hooks component 24.

Examples of diamond-shaped bonding patterns that fit the naval component 22 that can be used with some of the haka-20 components described herein are as follows. These comprise patterns with sides of about 0.6 cm x 0.6 cm, about 1 cm x 1 cm, about 1.3 cm x 1.3 cm, and about 2 cm x 2 cm.

The width of the bound regions 46 in the cross-section Bw shown in Fig. 7 may vary. In the foregoing characters of the diamond-shaped patterns described above, a suitable bond width (as measured from background 34) is from about 0.76 mm to about 1.3 mm.

; The cross-sectional areas of the bound areas shown in Fig. 3 are shown: tapering to become narrower from the first surface 31 to the second surface 33 of the female component 22. in terms of age. (For example, it may be less expensive to fabricate rolls whose patterned surfaces taper to form such bonds.),: 35 It should be understood that the non-woven female component 22 of the present invention shown in the drawings is for purposes of illustration 23 113742 only. . Obviously, there are many possible combinations of the different types of non-woven fabrics and backgrounds described herein. These combinations will be understood from the above description and the examples disclosed in the drawings. Thus, the non-woven female component 22 is not limited to the embodiments 5 shown in the drawings.

Thus, the present invention provides a low cost female component for a re-attachable fastening device. The female component 22 comprises a non-woven fabric 30, which features are specifically adapted to receive the hook 28 of the compatible hook component 24. The function of the fibers 36 of the non-10 woven fabric 30 is to cling to the individual hooks 28 of the compatible hook component 24. The female component 22 is specially formulated to grip the hooks of a compatible hook component. Thus, the female component of the present invention does not have relatively high costs for conventional loop components.

As a result, the fastening means 20 is particularly useful on the surface of disposable articles such as packaging, disposable suction articles, disposable wraps and the like. The female component 22 is more suitable for disposable articles because the fastening means on the surface of the disposable article is opened and closed much less times than on the surface of reusable articles. In general, the female component 22 must be just strong enough to provide a limited number of secure closures (up to a maximum of 10-20).

, ···. It should be noted, however, that the female component 22 may be # · much stronger for use on the surface of durable articles or 25 for other possible applications. This can be done, for example, by increasing the diameter or denier of the fibers 36, by attaching the fibers 36 more firmly to the backing 34, or by increasing the density of the fibers 36 relative to the number of staples 28: V. However, these changes also increase the cost of the female component 22 · · · v.

These are other properties of the fastening means, which may also be varied in other embodiments. For example, if single component 28 is sufficiently flexible in hook component 24, female component 22 having a smaller fiber diameter or weaker fibers may be used. In these cases, the claws 28 may open to release mechanical adhesion to the fibers 36 of the nonwoven fabric 30 before these fibers 36 break.

t 24 113742 This means that the hooks can act as a "release mechanism" for opening the attachment.

The female component 22 may also be used in conjunction with lower cost hook components having more fragile claws. In such cases, the fibers 36 of the non-woven fabric 30 may advantageously act as a "decay mechanism" to permit release of the hooks 28 when the fastening device is opened.

3. Compatible hook component

A compatible hook component 24 is shown in the drawings at a plurality of locations.

The term "hook component", as used herein, is used to indicate a portion of the fastening means 20 having gripping elements such as claws 28. The term "hook" is not limiting in the sense that the gripping elements may be of any shape known in the art or to the female component 22.

The hook component 24 comprises a base 26 having a first surface 27 and a second surface 29 and a plurality of gripping elements 28 extending from the first surface 27 of the base 26. Each gripping element 28 is shown to comprise 20 preferably a shaft 40 supported at one end by a base 26; which is disposed on the end of the arm 40 opposite the base 26.

The hooks components 24 used with the female component 22 of the present invention may be conventional, commercially available hooks. However, the hook component 24 is not limited to conventional materials with flexible, flexible hooks. In suitable hook components I »:. ! can be less expensive, relatively inflexible, more fragile.

The hook components 24 used with the female component 22 of the present invention may have blunt ends 38. The portion of the ends 38 of the hooks 28 which is blunt is the portion indicated by the peak 39 of the hook 28 in Figure 6. The top 39 30 first contacts the female component 22 of the present invention. ,> * when the female component 22 and the complementary hook component 24 are placed with one another against the surface. This portion is called the peak of the hooks 28 because it is !: * the portion of the hooks 28 that is at most perpendicular to the base 26 of the hook component 24. As used herein, the term "blunt" means that the tip 39 is dull in that it edge or tip that is not sharp.

> »· 25 113742

The end 39 of the hook 28 having a blunt end may be rounded, flat or any other shape that does not give a sharp tip.

Thus, female component 22 of the present invention does not require the use of specially made rigid hooks. However, it is possible that all forms of hooks, including such sharp claws, are used with the naa-5 heavy component 22.

A suitable hook component 24 may comprise a plurality of shaped adhesive elements protruding from the woven backing, such as a commercially available material called "Scotchmate", product number FJ3402, available from the Minnesota Mining and Manufacturing Company, St. Paul, Minnesota. The gripping elements may have any shape known in the art, such as hooks, "T's", sponges or other forms. A particularly preferred hook component is described in U.S. Patent 4,846,815, entitled "Disposable Diaper Having An Improved Fastening Device", issued to CL Scripps on July 11, 15, 1989. Another particularly preferred hook component is described in EP Application No. 0 381 087 A1. , entitled "Refas-Tenable Mechanical Fastening System and Process of Manufacture Therefor", published August 8, 1990 by Dennis A. Thomas. The disclosure of these patents and all other patents, patent applications and publications referred to in this application is hereby incorporated by reference.

(It should be understood that the various parts of the hook components may be explained in these references with slightly different terminology than that used herein. However, the drawings and constituent parts of this reference may be compared to those of the references to easily locate the corresponding parts of the hook components in these 25 publications.)

The hook component 24 can be made from a wide variety of materials. Such suitable materials include, but are not limited to, nylon, polyester, polypropylene or any combination of these or other materials.

The size 38 of the ends 38 of the staples 28 defines, as noted above, the open space required between the fibers 36 of the nonwoven fabric. Some non-limiting examples are given below of the sizes of the hooks 28 useful with the female component 22 of the present invention.

One suitable hook component 24 has T-shaped claws 28, 35 having the following dimensions. The length I of the head is about 1 mm, the width w is about 0.2 mm and: the height hi is about 0.3 mm. If this type of hook component is used, the openings between the fibers 36 of the non-woven fabric 30 should be slightly smaller, about 1 mm larger than about 0.2 mm (or should easily spread to these dimensions without puncturing). The thickness of the non-woven fabric 30 should be greater than about 0.3 mm.

Another suitable hook component 24 has upside down inverted "J" shaped hooks 28. (Hooks 28 of such hook component 24 could also be said to resemble caramel canes.) In other variations, such a hook could resemble an inverted upper case letter "L". Such splints could have the following dimensions. The length I of the head is about 0.5 mm, the width w is about 10 0.2 mm and the height hi is about 0.3 mm. If this type of hook component is used, the dimensions of the openings between the fibers 36 of the nonwoven fabric 30 should be slightly, about 0.5 mm larger than 0.2 mm (or easily spread to these dimensions without being pierced). The thickness of the non-woven fabric 30 should be greater than 0.3 mm.

Still other hook components 24 could have claws that are Vz or 1/4 smaller than those described above.

4. Examples of uses for the re-attachment fixture

The fastening means 20 of the present invention is particularly useful in disposable articles, particularly disposable suction articles.

20 As used herein, the term "disposable suction article" refers to articles that absorb and contain body fluids. More specifically, this term refers to articles that are placed against or near the body of the user to absorb and contain various fluids that are discharged from the body. The expression I · · “Disposable” means that such articles are intended to be discarded:: 25 after a single use (i.e., not to be washed or otherwise reused). Examples of disposable suction articles comprising diapers, pi-; Invalidity protectors, sanitary napkins, pads, patches and the like.

T; The fastening means 20 is shown in Fig. 10 disposed on the surface of a preferred embodiment of a disposable suction article 50, a disposable diaper 50. The term "diaper" as used herein refers to a protection commonly used by children and infirm persons, which is pulled up between the legs and fastened around the waist of the wearer.

The disposable diaper 50 has an inner surface (or body surface) 52 that is to be held close to the wearer's body. The diaper 50 has an outer surface (or garment surface) 35 54 that is intended to be placed near the wearer's wear when the diaper 50 is used. The mantle 50 has two waist regions designated as the first 27 113742 waist region 56 and the second waist region 58. The mantle 50 has two spaced apart longitudinal edges 60 and two spaced transverse or end edges 62.

The disposable diaper 50 comprises a main portion 51 and a mechanical fastening system such as a tape fastening system or simply a "fastening 5 system" 72. The main 51 portion of the diaper 50 comprises a liquid-permeable topsheet 64, an absorbent core 66, a liquid-impermeable backing 68, and an elastic 66, back cloth 68 and elastic member 70 may be assembled into a number of well known shapes.

Several examples of diapers to which the present invention 10 can be readily applied are disclosed in U.S. Patent Re. 26,151, entitled "Disposable Diaper" and reissued to Robert C. Duncan et al., January 31, 1967, U.S. Patent 3,860,003, titled "Contractible Side Portions For Disposable Diapers", issued KB Buell, January 14, 1975, U.S. Patent 4,695,278, entitled 15, Absorbent Article Having Dual Cuffs, issued to Michael I. Lawson, September 22, 1987, U.S. Patent 4,834,735, titled Absorbent Article Having Dual Cuffs "High Density Absorbent Members Having Lower Density And Lower Basis Weight Acquisition Zones", granted to Miguel Alemany et al., May 30, 1989, and U.S. Patent 4,909,20,803, entitled "Disposable Absorbent Article Having Elasticized"

Flaps Provided With Leakage Resistant Portions "and issued to Mohammed I. Aziz et al., March 20, 1990. It should be understood, however, that the fastening means 20 of the present invention is not limited to use with any particular diaper structure or form. for.

The fastening system 72 of the jacket 50 comprises the present invention: a fastening means 20 among other components. The fastening system 72 may be in the form of:,:: a well-known configuration or structure currently in use.

The V fastening system 72 is preferably a strip fastening system, preferably a tape: Y: mini strip fastening system.

The tape strip fastening system may comprise some well known tape strip configuration and construction currently in use. Affordable ·. the tape fastening system utilizes a Y tape strip, which is described in detail in U.S. Patent No. 3,848,594, entitled "Tape

Fastening System For Disposable Diaper "issued to KB Buell Y 35 November 19, 1974. Alternative low cost adhesive tape fastening systems are described in detail in EP Application Publication 0 233 704-A, entitled" Disposable Diaper Having Wide Tapered Fastening Tapes " and published on August 26, 1987 by HR Burkhart and Kenneth B. Buell, previously cited in U.S. Patent 4,846,815 to CL Scripps, and U.S. Patent No. 4,963,140, 5, titled "Mechanical" Fastening Systems with Disposable Means for Disposable Absorbent Articles "and granted to Anthony J. Robertson et al., October 16, 1990.

In still other preferred embodiments, the female component 22 of the fastening system 72 could comprise a structural member such as a patch on one surface (or other suitable locations) of the main body 51 of the diaper 10 to form an "inner fastening member" as described in U.S. Patent 4,699,622. An Improved Side Closure "and granted to JW Toussant et al on October 13, 1987.

The tape fastening system 72 shown in Figure 10 is not a limiting example of a type of fastening system 20 that can use the fastening device 20 of the present invention. The tape fastening system 72 comprises a tape die 74 having a first fastening element 72a and a second fastening element (or . The second fastening element 72b may be mechanically fastened to the first fastening element 72a.

Preferably, the first fastening element 72a comprises a hook component 24. The hook component 24 provides jaws 28 extending from a tape strip 74. In a preferred embodiment of the disposable diaper 50, the nonwoven female component 22 of the present invention comprises a second fastening element 72b. . In other embodiments, the locations of the components of the fastening device 25 of the present invention could be reversed such that the first fastening element 72a comprises a female component 22 of a non-woven fabric and the second: the fastening element 72b comprises a hook component 24.

As shown in Fig. 10, the non-woven female component 22 is preferably in the second waist region 58 of the diaper 50. In a preferred embodiment of the disposable diaper 50, the fibers 36 are oriented in the non-woven fabric of the female component 22. The female component 22 is oriented such that the fibers 36 in the non-woven fabric 30 extend substantially parallel to the longitudinal edges 60 of the shell 50. This orientation directs the fibers 36 generally perpendicular to the clamping means 20 in the direction of the shear forces applied during operation. In this configuration, the fibers 36 provide maximum resistance to peeling and shearing forces. However, the female component 22 29 113742 may be oriented in the second waist region 58 in any manner with the fibers 36 extending in any direction.

In use, the diaper 50 is applied to the wearer by placing a first waist region 56 below the user's back and pulling the remainder of the diaper 50 between the user's legs so that the second waist region 58 is positioned across the user's front. Tape strips 74 are then positioned close to the female component 22 disposed on the outer surface 54 of the second waist region 58 so that the hook 28 disposed in the tape strip 74 engages the female component 22 to form a side closure.

10 Method for making a female component

The method or process for making the female component of the present invention is shown in FIG. 11 in schematic form.

The apparatus necessary for making the non-woven female component 22 of the present invention is designated 100. The apparatus 100 comprises a first-feeder 102 and a second feeder 104. The feeders 102 and 104 feed to the system materials comprising a non-woven female component 22 and background 34.

The apparatus 100 may also comprise an element providing a embossed surface such as an embossed roll 110 (which may be patterned) and a lower portion 20 such as an anvil roll 112. The embossed roll 110 and anvil roll 112 define a contact surface 114. The contact surface 114 is where laminates of fabrics or other materials are bonded together. The bound fabric 124 can pass to the winder roll 116 where it is wound for later use. The individual parts of the apparatus 100 will be described in more detail below.

4 ·; In the apparatus 100 shown in Fig. 11, a preferred method is non-. ': For making a woven female compass 22 comprises a non-woven fabric and a backing: feeding materials into the system and binding them. The materials may be bonded by a variety of methods including, but not limited to, adhesives, ultrasound and heat / pressure processes.

A preferred method of bonding materials is to release a combination of materials between two heated rolls, one of which has a pattern on its surface, and by pressing the bond pattern on the materials. One method of heat / pressure bonding that could be used is described in U.S. Patent No. 4,854,984, issued to Ball et al., Issued August 8, 1989 (provided that the 30,117,442 patterned cylinder disclosed herein forms bond regions that meet the requirements herein). criteria stated in the explanation).

The first feeder 102 feeds the first material 118 used for the non-woven fabric 30 into the system. The first material 5 118 may be one of those materials defined as suitable for use in a nonwoven fabric 30 in Chapter 2 of this specification. Thus, the first feeder 102 could be any conventional device used to introduce the material into the laminating process. The first feeder 102 could be, but need not be limited to, an unwinding roll, a fabric or tissue producing machine, or a hopper for feeding loose fibers into the system.

In a preferred embodiment of the method of the present invention, the first feeder 102 comprises either a spunbonded fiber feed or a conventional machine for doing so. Preferably, the first feeder 102 feeds a layer of loose (i.e., unbound) fibers of continuous length 15 into the system. These fibers are preferably uniformly deposited on a suitable surface. These fibers could be placed on a surface such as the material described below, which comprises a backing 34. In other alternative embodiments, instead of the first material 118 being a layer of loose fibers, it could be fabric staple fibers or fabric bound fibers.

The material 118 used to form the non-woven fabric 30 preferably has sufficient thickness or flair built into its structure to accommodate the hooks of the compatible hook component. If not, it is possible that the material 118 used to form the nonwoven fabric 30 could be fluffed during the female component making process. 25 If this is the case, the equipment could include means for wiping 1 »* · material. Such means could include a conventional corrugation and corrugation method (i.e., a plating and correcting method represented by box 128 in Figure 11). The method requiring such an additional step is:, i ': generally less preferred.

Regardless of the form in which the fibers used to form the non-woven fabric 30 are fed to the apparatus (be it fabric or loose, unbound fibers), the fibers of the first material 118 are preferably oriented mainly in the machine direction. This provides a female component 22 where the fibers 36 have the desired single directional orientation that is preferred: 35 to hold the hooks of the compatible hook component.

»31 1 13742

The term "machine direction" (MD) refers to a direction parallel to the flow of materials 118 and 120 through the apparatus 100. "Direction across machine" (CD) is perpendicular to machine direction. These directions are indicated by arrows in Figures 11 and 12.

The second feeding device 104 feeds to the system a second material 120 which is used for the background 34. The second material 120 may be any of the materials defined as suitable for use as backdrop 34 in Chapter 2 of this specification. Thus, the second feeder 104 could be one of the devices used to introduce the material into the lamination process. The second feeder 104 could be, but is not limited to, an unwinding roll, or a fabric or fabric making machine such as a weaving machine, a knitting machine, a conventional carding machine or a spinning machine.

As noted above, background 34 may be optional. If the backing 34 is removed, the task normally performed on the backing can be performed on a base 15 to which the female component 22 is attached. The second material 120 could therefore be a substrate such as a material used as a disposable diaper backing.

In other alternative embodiments of the apparatus 100 shown in Figure 10, an additional alternative feeder similar to that shown as the third feeder 106 could be provided if it is desirable to construct a non-woven female component from more than two materials. Such an additional feeder could be used, for example, to make a multilayer non-woven fabric 30 or to make an alternative embodiment with a skin-friendly layer as described above. Still • t '*! in other alternative embodiments, one or more materials introduced into the system could be folded to provide one or more layers of such material.

:: The component that gives an embossed surface can be anywhere * .: in a suitable configuration. It can be, for example, an embossed plate or a cylinder.

: Preferably, it is a patterned cylinder such as a patterned cylinder 110. The patterned cylinder 30 110 is used to bind the material 118 used to form the nonwoven fabric 30 into the backing 34. The pattern forms bound areas 46 on the female component 22. The pattern should be relief a relatively small portion of the first material 118 is compressed during the process. The remainder of the first material forming the non-woven fabric 30 should not be compressed in order to maintain the total swept property of the first material 118.

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The pattern shall form a bond having the properties described in section 2 above. Thus, the space between the bound regions 46 must be sufficient so that the hook 28 of the compatible hook component 24 can easily penetrate the non-woven fabric 30. However, the space between the bound regions 46 should not be so large relative to the length of the fibers used to form the non-woven fabric 30. that there is an excessive amount of fibers with unbound, loose ends.

The surface of the patterned roll 110 is shown in more detail in Figure 12. The surface defines smooth spacers 132 and depressions 134. The smooth spacers 132 and depressions 134 of roll 110 have a number of properties. These include roll depth or recess depth, pattern dimensions, etc. These properties vary depending on the materials used for the non-woven fabric 30 and the backing 34 and the type of bonding pattern desired.

The patterned roller 110 shown in Figure 12 is used to form a preferred diamond-shaped binding pattern shown in Figures 1-3.

The depth of the recesses 134 (or the height of the smooth spacers 132) should generally be greater than the sum of the thickness of the first material 118 and some other materials used to form the multilayer non-woven fabric. Typically, the recesses have a depth of about VA times the sum of the thicknesses of such materials.

The patterned roll 110 has smooth spacers 132 that are substantially square in shape and are rotated about 45 degrees to the machine transverse direction .... These squares may have some suitable dimensions. For example, these squares may be about 0.6 cm x 0.6 cm, about 1 cm x 1 cm, about 1.3 cm x 1.3 cm, and about 2 cm x ♦ · 25 cm to form the bonds described in Chapter 2 above. . The width of such smooth spacers 132 may be, for example, about 0.76 mm x 1.3 mm.

The embossed roll 110 may be and preferably is heated. The temperature at which the rolls, such as the embossed roll 110, are heated depends on the materials used to form the non-woven fabric 30 and the backing 34. In the preferred embodiment shown, the first and second materials 118 and 120 consist of polypropylene. When using polypropylene, the embossed roll 110 is preferably heated to about 155 ° C to -168 ° C.

Preferably, the lower member is a cylinder having a flat surface such as an anvil roll 112. The lower member 112 is preferably also heated. Preferably, the low roller 112: 35 is heated to a temperature of about 104 ° C to 110 ° C when polypropylene materials are used to form the female component 22. The lower roll 112 33 113742 rotates in the opposite direction to the embossed roll 110 (i.e., the two rolls rotate in opposite directions).

The first and second materials 118 and 120 are bonded together as they pass through the contact surface 114. The materials are bonded by applying heat and pressure 5 to rolls 110 and 112 at contact point 114. In a preferred embodiment of the method of the present invention, the rolls rotate to form bonded fabric 124 at a speed of about 30.5 m / min. The rollers exert a pressure of about 50 to 70 kg / linear centimeter as measured across the point of contact in the cross machine direction.

In alternative embodiments of the method of making the female component of the present invention, adhesives may be used to bond materials 118 and 120 together instead of heat or heat and pressure. In the adhesive binding method, the adhesive could be applied by any suitable commercial adhesive applicator 108. The adhesive applicator preferably applies an adhesive to a pattern similar to that formed by the smooth spacers 132 of the patterned roll 110. In such adhesive bonding methods, patterned rolls 110 could be replaced by another flat roll. However, in most cases, it is preferable that the patterned roll 110 is still operated so that not all of the first material 118 is compressed and the swollen property of the first material 118 is retained. Such adhesive bonding methods could be performed without applying pressure. However, in such cases, pressure is also applied by rollers.

In yet other alternative embodiments, rolls 110 and 112 ... could be replaced with a commercially available ultrasonic welding device.

The bobbin roll 116 collects the material of the female component in a bonded (• 25 fabric 124. The female component roll can be taken from the reel 116: and cut to a suitable size for use in a re-attachable device: with a suitable hook component. in alternate embodiments, the rewind roll 116 30 could be removed and the bonded fabric 124 could be fed directly to a convenient location on the diaper production line The bound fabric 124 could be cut and secured directly to the appropriate locations on the fabric of the jacket material.

Thus, the non-woven female component 22 can be made relatively inexpensively compared to conventional loop materials. This method eliminates the need to fluff or process material to form single loops. The method results in a lower cost female component because the 34113742 female component can be manufactured at a lower cost and by a relatively straightforward binding or lamination process instead of conventional weaving, knitting, crimping or corrugating methods.

While specific embodiments of the present invention have been described and explained, it should be apparent to those skilled in the art that various other modifications and variations can be made without departing from the spirit and scope of the invention. It should be understood that all constraints and ranges defined by the fastener in the foregoing description include all narrower ranges and ranges within the defined ranges and ranges. For example, if the range 10 is defined to be about 6-42 g / m 2, all narrower ranges such as about 10 -40 g / m 2 and about 20-30 g / m 2, etc. may thus be claimed, although these ranges are not listed separately . Therefore, the appended claims are intended to cover all such changes and modifications within the scope of the present invention.

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Claims (8)

A female component (22) for an attachable fastener (20), which female component (22) pre-engages in a complementary, hooked fastener (24) having a base (26) with individual hooks (28) whose blunt the heads (38) extend leaking from said base (26), said female component comprising: a supporting structure (34) and a nonwoven fibrous web (30), said nonwoven web (30) having a basis weight of about 6 to 42 g / m 2, so that there is space between the fibers of the nonwoven web (30) and said nonwoven web (30) comprises a plurality of fibers (36), the area of the pane being occupied by bonds (42). ) between which the fibers of the nonwoven web (30) are less than about ten percent of the total area of said nonwoven web (30), wherein a plurality of fibers are arranged between two adjacent bonded points (46) between the nonwoven web (30). ) and the supporting structure (34), characterized in that said female component (22) has a pian, outside facing surface. a, wherein said nonwoven web (30) is secured to said supporting structure (34) with the bonds (46), such that the total bonded area in plane view occupied by both the bonds between the fibers of said nonwoven web (30) and the bonds 20 between said nonwoven web (30) and said supporting structure (34) is between about 10 percent and 18 percent of the total area of the female component (22). Female component (22) according to Claim 1, characterized in that: ":" that the surface weight of said nonwoven web (30) is about 18-24 g / m2 and consists of a ··· number of fibers whose denier is about 0.5 - 15, wherein the area in pie view occupied by bonds (42) between which heist of said fibers in said nonwoven web is less than about six percent of the total nonwoven web (30) of said nonwoven web; web is secured to said supporting structure (34) with binding. means (46) which form spaced apart regions which are about half or less of the length of the fibers in the nonwoven web. 3. Female component (22) according to claim 1 or 2, characterized in that the fibers in the nonwoven web (30) are wrinkled and said nonwoven web is flexible. 4. Female component (22) according to claim 1, 2 or 3, characterized in that at least some of the fibers (36) in said nonwoven web (30) are fused in the supporting structure (34), so that they share of said fibers (36) adjacent said supporting structure comprises tapered parts thinner than the other parts of said fibers, said tapered parts of said fibers constitute the weakest part of said fastening device as it is subjected to removal of the hooks (28). in said complementary, bracket mounting component (24). 5. Fastening device (20), characterized in that it comprises a hooked fastening component (24) comprising a base (26) and a plurality of hooks (28) extending from said base, and a female component (22). according to claims 1, 2, 3 or 4. 6. Fastening device (20) according to claim 5, characterized in that the hooked fastening component (24) comprises hooks (28) which are relatively inflexible, so that said hooks are released from mechanical lacing with the fibers of said nonwoven web (30) and said fastener is opened by breaking the fibers of said nonwoven web (30) adjacent to the position of the bonds (46) between the nonwoven web (30) and the supporting structure (34). Absorbent, single use article (50), characterized in that it comprises a mechanical fastening system (72) arranged on a body part (52) and comprising a tab (74) fixed in said body part (52) adjacent each longitudinal edge. (60), each of said tabs (74) comprising a hooked mounting component (24) arranged on at least a portion of said tab (74), and a female component (22) according to claim 1 or 2, arranged on said outer surface (54) of said main part (52), which female component (22) can be mechanically fixed in said hitched mounting component (24). Absorbent, single use article (50) according to claim 7, characterized in that the fibers in said female component (s) of said nonwoven web (30) are generally parallel to said absorbent web for disposable articles intended for the longitudinal edges (60) of articles (50).